Building blocks, bricks, tile, panels and the like

ABSTRACT

THE BLOCKS ARE SQUARE IN FACE AREA, AND HAVE CENTRALLY EXTENDING DOVETAIL GROOVES IN BOTH RECTANGULAR DIRECTIONS ACROSS THEIR INTERLOCKING FACES, LEAVING HALF RIDGE PORTIONS ONLY AT THE CORNERS OF THESE FACES OF THE BLOCKS IN ONE LAYER OF A WALL FOR INTERLOCKING WITH THE SINGLE GROOVES OF THE BLOCKS IN THE OTHER LAYER, WHICH ARE ARRANGED SO THAT ALTERNATE BLOCKS IN SAID OTHER LAYER HAVE   THEIR GROOVES IN ALTERNATE HORIZONTALLY AND VERTICALLY SLIDABLE ENGAGEMENT WITH SAID CORNER RIDGE PORTIONS OF SAID CROSS-GROOVED BLOCKS, PROVIDING A COMPLETE INTERLOCK AGAINST SLIDING BETWEEN LAYERS IN EITHER RECTANGULAR DIRECTION.

Feb. 16, 1971 R. s. GREGOIRE 3,562,989

BUILDING BLOCKS, BRICKS, TILE, PANELS AND THE LIKE Original Filed July 13, 1967 6 SheefcsSheet 1 INVENTOR.

RESTA 3. GR EGOIR VMzA Fe 16, 1911 R. s. GREGOIRE 3,562,"?5 9 BUILDING BLOCKS, BRICKS, TILE, PANELS AND THE LIKE Original .Filed July 13. 1967 6 Sheets-Sheet 2 Fly. xv/

INVENTOR RESTA S. GR EGOIRE Feb. 16,1971 R. $.GREGOIRE 3,562,989

BUILDING BLOCKS, BRICKS, TILE, PANELS AND THE LIKE Original Filed July 13. 1967 6 Sheets-Sheet 3 Ca -7 (r i' I I M20 H0 Fig. xv/// INVENTOR R ESTA S. GREGOIRE Feb. 16, 1971 R. S.GREGOIRE 5 5 BUILDING BLOCKS, BRICKS, TILE, PANELS AND THE LIKE Original Filed July 13, 1967 6 Sheets-Sheet 4 V Fig. xx 10/ INVENTOR.

- F;g. XXV/ll i i Feb. 16, 1971 R. s. GREGOIRE f 356259.89

BUILDING BLOCKS, BRICKS, TILE PANELS AND THE LIKE Original Filed July 13. 1967 6 Sheets-Sheet 5 i I I42 INVENTOR.

RESTA S. GREGOIRE a/max W Feb. 16,1971 R. s. GREGOIRE 62,

BUILDING BLOCKS, BRICKS, TILE, PANELS AND THE LIKE M Original Filed July 13. 1967 6 Sheets-Sheet 6 F19 XXX/l INVENTOR.

RESTA s'. GREGOIRE Max M United States Patent 3,562,989 BUILDING BLOCKS, BRICKS, TILE, PANELS AND THE LEKE Resta S. Gregoire, Newport, Pa, assignor to Z-Lock Block Co., Newport, Ia., a corporation of Delaware Application Dec. 6, 1963, Ser. No. 784,282, which is a continuation of application Ser. No. 653,170, July 13, 1967. Divided and this application June 24, 1969, Ser. No. 850,291

Int. Cl. Etl lb 2/72; Ethic 1/10, 2/46 US. Cl. 52-279 1 Claim ABSTRACT OF THE DISCLOSURE The blocks are square in face area, and have centrally extending dovetail grooves in both rectangular directions across their interlocking faces, leaving half ridge portions only at the corners of these faces of the blocks in one layer of a wall for interlocking with the single grooves of the blocks in the other layer, which are arranged so that alternate blocks in said other layer have their grooves in alternate horizontally and vertically slidable engagement with said corner ridge portions of said cross-grooved blocks, providing a complete interlock against sliding between layers in either rectangular direction.

This is a divisional application of SN 784,282 filed Dec. 6, 1968, now abandoned, which is a continuation of SN 653,170 filed July 13, 1967, now abandoned.

This invention relates to a building system using interlocking blocks, bricks, tiles, panels and the like, requiring no mortar, cement or other binder materials in the construction of walls, roofs, decks, road beds, side walks, pillars, silos, enclosures, swimming pools, ducts, linings and the like.

The basic unit in a system of this type has a rectangular face area of a suitable unit height and a unit length and has alternate dove-tailed grooves and ridges on its internal face for slidably interlocking with corresponding ridges and grooves respectively, of similar blocks laid in the opposite layer of a double layer wall or slab during its erection, the blocks in one layer being laid in overlapping relation with respect to those in the other layer while lining up the internal faces of the opposite layers to form continuous grooves and ridges in the adjacent blocks, so as to slidably interlock with the ridges and grooves of the overlapping blocks of the opposite layer as it is slid into place to rigidly interlock said adjacent blocks in the direction normal thereto.

The object of this invention is to provide a system of interlocking block forms that require no application of any binding materials to hold the blocks together as they are laid in overlapping interlocked relation in the construction of straight or curved wall structures including floors, roofing and beam structures, and having corners and cross walls at any desired angles as well as openings for doors, windows and the like.

A further object is to provide a basic form of block or panel having alternate dovetail grooves and ridges in at least one face, that may be used in building a multilayer wall, floor, road bed or roof slab, etc. in which the grooves and ridges of the blocks or panels in one layer are interlocked with the ridges and grooves of overlapping adjacent blocks in the adjacent layer, so that no cementing binder material is necessary to hold the blocks in place as they are laid successively in their overlapping relations in the several layers of the wall or slab.

A further object is to provide colored or other distinctive finishes on the external faces of these blocks to enable their arrangement or rearrangement into desired ice artistic designs or mosaic patterns on either side of a double layer wall or other slab, as it is built or rebuilt.

A further object is to make the blocks and panels of formed sheet material or extrusions having axially extending alternate dovetail shaped ridges and grooves on one face to provide the interlock between adjacent blocks or panels in one layer and their overlapping panels in an adjacent layer.

A further object is to make these sheets or extrusions of various multiple unit lengths and/ or multi-unit heights, so as to enable the construction of extensive walls with fewer blocks or panels.

A further object is to make these blocks or panels of formed sheet material having limited flexibility in the horizontal direction, whereby curved or circular walls, cylinders or tubes may be built with substantially sealed joints and without using any piercing connections between the blocks or panels, or any welded joints, to hold the walls together.

A further object is to provide interlocking blocks for interior and exterior rectangular corners as well as for T and wall corners.

A further object is to provide blocks for forming i11- terlocking frames in openings in the wall for doors, windows, etc.

A further object is to provide matching semi-circular grooves in the side edges of these blocks, forming a circular bore in the vertical joints between blocks for the reception of sealing materials, and circular sectioned sealing strips adapted for insertion in these bores and sealing strips for the horizontal joints between blocks in each layer of the wall.

A further object is to provide blocks of this type having integral ledge portions extending outwardly from their outer faces or inwardly from their internal faces as may be desired.

A further object is to provide blocks for forming an eave corner having a suitable angle with respect to the vertical wall.

A further object is to provide blocks having both vertical and horizontal dovetail grooves and ridges for use in one layer of a wall to interlock with blocks in the other layer having only one directional grooves and ridges which are alternately slid into the vertical and horizontal grooves of overlapping blocks in said one layer, thus causing a rigid interlock in both directions between the layers.

A further object is to provide the grooves and ridges on both faces of each block so as to enable the construction of a road bed with vertically interlocked blocks or a multi-layer wall having more than two layers.

Other and more specific objects will become apparent in the following detailed description of some forms of the invention as illustrated in the accompanying drawings, wherein:

FIG. I is a perspective view of a basic unit block of the present building system, having a substantially square face area,

FIG. II is a similar view of a fractional unit having half the height of this basic unit,

FIG. III is a similar view of a double length unit having twice the length of this basic unit,

FIG. IV is a similar view of a fractional unit having half the length of this basic unit,

FIG. V shows a rectangular corner block of a form that may also be used as a T corner or cross-wall corner connecting or cross block,

FIG. VI shows another form of rectangular corner block,

FIG. VII shows a one and a half length form of this basic unit,

FIG. VIII shows this basic unit with a solid column forming extension on its external face with a nesting rectangular pocket in and projection on the opposite vertical ends respectively of the extension,

FIG. IX shows this basic unit having a hollow rectangular column forming extension on its external face,

FIG. X shows a cap unit having an interlocking portion of half. the height of this basic unit for finishing the top of a wall or other slab.

FIG. X1 is a modification illustrating a double length unit having its ridges formed of a different material from the body of the block, e.g. to form an internal insulating layer in the wall,

FIG. XII shows this basic unit provided with tongue and groove joining configurations in the top and bottom to provide some sealing as well as more perfect alignment of the external faces of the blocks, and semi-circular grooves in the side ends of the block to form continuous vertical bores in each wall layer for receiving sealing material in the vertical joints,

FIG. XIII is a plan view of the top of a wall portion showing a joint forming a vertical bore with a rod of flexibly resilient sealing material inserted therein having radially extending fins for resilient contact with the sides of the bore, and a flat sealing strip on top of the row of blocks in one layer of the wall ready for laying the next row of blocks,

FIG. XIV shows a cross sectional view of a rod of flexibly resilient sealing material for use in the bores formed in the vertical joints,

FIG. XV shows a block unit with another arrangement of the vertical grooves, locating them nearer to the external face of the block, and no horizontal tongue and groove provisions in the top and bottom of the block,

FIG. XVI shows a vertical section through a portion of a wall and a base groove in which the laying of the wall was started,

FIG. XVII shows another form of rectangular ledge projection extending from one side of the external face of the basic unit,

FIG. XVIII shows a portion of a stairway built entirely of this type of interlocking blocks of suitable dimensions,

FIG. XIX shows a plan view ofa portion of a patio with a zig-zag form of wall or parapet around it showing the use of rectangular corner blocks and an obtuse angular corner block,

FIG. XX is a perspective view of one of the obtuse angle blocks,

FIG. XXI is a unit block with a ledge projection extending from its internal face,

FIG. XXII is a unit block with a ledge projection extending from its external face,

FIG. XXIII is a vertical frame block for door and window opening integral with a half unit length finishing block for the edge of the wall opening,

FIGS. XXIV and XXV are perspective and end views of a sill block for mounting over the top or under the bottom of the side frames of a window or door opening,

FIG. XXVI is a plan view of a portion of a wall finished off at its vertical edge by a vertical frame block,

FIG. XXVII is a perspective view of a double length half height block having a base footing block extending horizontally at its base for starting a wall and its base simultaneously,

FIG. XXVIII is an enlarged perspective view of a portion of a flexible resilient sealing strip for use in the horizontal joints if desired,

FIG. XXIX is a perspective view of a portion of a building with a multi-ridged roof composed of rectangular corner blocks with 135 angle blocks at the sides of the roof for finishing off the top of the side walls with a half height block portion extending downwardly,

FIG. XXX is a perspective view of one of the 135 blocks,

FIG. XXXI is a perspective view of one of the rectangular corner blocks used in the roof,

FIG. XXXII is a perspective view of a unit block having dovetail grooves in both directions, for making alternate blocks in each row of one layer slide into this type of blocks in the other layer alternately vertically and horizontally to provide rigid interlocks between the blocks of the opposite layers in both horizontal and vertical directions,

FIG. XXXIII is a perspective view illustrating the use of blocks having the groove and ridge structure on both faces to form a third or middle layer in a three layer wall.

Referring now to the drawings, FIG. I shows the basic unit block 2 having a rectangular face area of any suitable unit dimensions U and X and a thickness substantially /3 of said unit length dimension U of the rectangular face, the depth of the groove 4 or height of the ridge portions 6 being about half this thickness or U/ 6. The thickness of a wall would be /2 of this unit length dimension. Obviously, these unit length and height dimensions U and X and the relations of the other dimension may be varied to suit material weight and strength requirements of any particular system.

FIG. II shows a fractional block 8 having the same configuration and dimensions except its height which is substantially /2 of a basic unit block 2. This block may be used in the first course in one layer at the base of the wall so as to start the vertical overlaps of the courses in the two layers as they are alternately built up by adding the successive courses.

FIG. III shows a multi-unit block 10 having a length of two units with a complete ridge 12 in the middle of the internal face, flanked by two grooves 4, leaving two ridge portions 6 at the sides of the internal face. Other multi-unit blocks may be made having unit length increments beyond this two unit length to any length desired, and/ or unit height increments over the unit height of the basic unit block to any height desired. For small thicknesses and/or light materials, it may be preferable to use larger multi-unit blocks within suitable weight limitations for easy handling.

FIG. IV shows a fractional unit block having half the length of the basic unit block with only portions 16 and 6 of a groove and a ridge respectively, which block may be used to fill in a horizontal overlap at the end of a course of blocks to square off the end of a wall.

FIG. V shows one form of corner or cross block 18 comprising a basic unit block having a half length block extending from one side of the external face of the unit block to provide the first block in the inner layer of the wall on each side of the corner or corners.

FIG. V1 is an alternate form of corner block 20 having a square corner post whose square cross-section has a dimension of /2 of a unit, and a half length block extending therefrom on each side of the corner to provide the first block in the outer layer of each wall extending from the corner.

FIG. VII shows a rnulti length unit block 22 having a length of 1 /2 units.

FIGS. VIII and IX show unit blocks 24 and 32 with a solid rectangular pillar portion block 26 and a like hollow block 34 respectively extending from the external faces of said unit blocks. The solid block 26 may be pro vided with a nesting pocket 28 in one end of said block and a corresponding projection 30 at its other end.

FIG. X shows a half unit height cap block 36 having a cap 38 extending from the top of said half unit height block portion to fill out the vertical overlap of the top course in one layer and simultaneouly provide a cap over the entire thickness of the wall.

FIG. XI shows a double length block 48 having ridges made of an insulation material 50, to provide a substantially continuous middle layer of insulation in the wall made with this type of blocks.

FIG. XII shows a unit block 52 provided with semicircular grooves 54 in the outer sides of its ridge portions 6. The circular bores formed by these grooves in the vertical joints between blocks may be filled with sealing means, such as 70 (see FIG. XIV) comprising a flexible resilient material and normally having the form of a rod 66 with radially extending axial fins 68 extending to a diameter D substantially greater than the diameter D of the circular bores, whereby insertion of the sealing means with a spiral motion will provide a good seal in said vertical joints. Tongue and groove means 56 and 58 may be made at top and bottom of the block to provide a weather seal in the horizontal joints as wel as to improve alignment of the faces of the blocks.

FIG. XII is an enlarged detail plan view of a portion of a wall, showing portions of three interlocked blocks 2, two of which, in the one layer, have vertical semicircular grooves 54 forming the bore at the joint between the two ridge portions 6, into which a sealing material 70 has been inserted to form a good water tight seal at the joint. These sealing grooves 60 may be moved close to the external face of the block as shown in the enlarged view of block 8 in FIG. XV to form the bore shown in dotted lines in FIG. XIII which shows a sealing strip 134 placed over the ends of the sealing means 70 in the vertical bores to provide continuous water tight seals throughout the vertical and horizontal joints in each layer of the wall.

FIG. XVI shows a base 74 for a wall started in a groove 72. Any arrangement of overlapping blocks may be used in building the wall, as illustrated, e.g., in the portion shown in FIG. XVII.

FIG. XVII shows another form of useful block 76 comprising a basic unit block with a rectangular projection 78 extending from the external face of the block to provide a flat column fixed to the side of the wall, or just a projecting portion thereof wherever desired.

FIG. XVIII shows how a stairway might be assembl d using suitably dimensioned corner blocks 120 for the steps, starting at the bottom where the floor is composed of double length blocks 110 and unit blocks 102 and finishing off the lower layer of the top tread with a half length block 104. The stepped side walls may be made with double length blocks 110 and unit blocks 102 as shown.

The corner blocks 120' may be used to form a zig-zag shaped enclosure or parapet around a correspondingly shaped floor made of suitably dimensioned blocks 110 and 110', as shown in FIG. XIX. A 135 angle corner block 92 is used at one end of the wall with a half length block 104 finishing off said end. Block 92 is shown in FIG. XX in perspective view.

Integral ledge portions 106 and 108 may be formed extending from the blocks internally as in block 75 or externally as in block 77. Block 96 is a half length block of a height suitable for framing the vertical edge of an opening in a Wall left open for a window or door. This block is inserted over each side edge of the opening as shown in FIG. XXV only after a sill block 98 (FIGS. XXIII and XXIV) is inserted over the bottom edge of the opening, and another sill block 98 is then placed over the tops of the vertical frame blocks 96 to form a base support for the upper edge of the wall opening.

The half height row of blocks used for starting one of the layers of the wall at the bottom may be formed integrally with their base portions 100 as shown in FIG. XXVI, so that they may be laid simultaneously as the footing for the wall.

A flexible resilient sealing strip 134 may be used in horizontal joints between blocks or between blocks and sills, to provide good waterproofing along with the vertical seals 70 in the bores formed between the side edges of the blocks by the semicircular grooves 60. The frame and sill blocks 96 and 98 may be provided with a rectangular groove 136 for receiving rectangular sealing strips to provide sealing between the window or door (not shown) and the frame of its opening.

A multi-ridged roof slab as shown in FIG. XXVIlI may be built of corner blocks 120 which may be prestressed or poststressed by mounting stretched steel reenforcing 6 strands in concrete set in the continuous axial bores 138 in the corners of the corner blocks 120. A angle block 140 may be used having a half unit height portion 142 for finishing off the top of the inner layer of the side wall, and an angular portion 144 forming the inner layer of the adjacent roof ridge.

A modified unit block is shown in FIG. XXXI which has groove and ridge portions in its internal face in both vertical and horizontal directions. In other words, in addition to the groove 152 and ridge portions of the unit block 2, another groove 154 is cut normally thereto through the ridge portions to form the corner ridge portions 156. As one layer of a wall is built by laying these blocks 150 in horizontal and vertical alignment, the blocks in the other layer may be laid in overlapping relation, sliding alternate blocks 2 horizontally and vertically into interlocked relation with corresponding blocks 150, so as to provide a rigid interlock between the layers in both horizontal and vertical directions.

The same result may be achieved, using blocks 150 throughout if their overlaps are other than half a unit vertically and horizontally in the opposite layers.

For a multi-layered wall having more than two layers, the intermediate layers may be formed of blocks such as 164- vvith ridges and grooves on both faces to match the internal faces of adjacent layers. These blocks may be provided with the semicircular grooves 60 in their vertical side edges. These blocks may also be laid in any direction across a whole road bed of any width and length. Obviously, it is immaterial whether the grooves and ridges on one of the faces of these blocks are lined up (as shown in FIG. XXXII or uniformly reversely offset with respect to those on the opposite faces (not shown), so as to form continuous matching ridges and grooves on the opposite faces of each layer as the blocks are laid therein.

The flexible resilient sealing strips 134 and rods 66 may be made of an impervious foam urethane or vinyl material. Another suitable material is a foam urethane with bituminous which has a somewhat better memory retention characteristic.

As may be readily understood from the above detailed descriptions, this system lends itself very well to building other than straight wall structures, including artistic and architectual design uses as well as toy building blocks. Miniature size unit blocks would be very useful to architects and engineers for making sample models of their various architectual and engineering designs. Also artistic mosaic designs could be created by artists and amateurs, embryo building architects and structural engineers, who could readily try out their skills and incidentally acquire more interest to experiment with different arrangements and structural forms without necessarily resorting to expensive full size materials.

Many other obvious modifications in the detail forms and arrangements of parts in this building system may be made without departing from the spirit and scope of the present invention, as defined in the appended claims.

What is claimed is:

1. A wall construction of concrete units assembled without a binder therebetween and comprising a plurality of linear wall segments each comprising a double layer of blocks with the blocks in one layer overlapping the blocks in the other layer both horizontally and vertically, said blocks having identical horizontal sections with the inner faces of blocks in one layer having alternate and equal vertically coextensive dove-tail grooves and ridges slidably interlocked with similar vertical coextensive dove-tail grooves and ridges in the inner faces of the blocks in the other layer, a corner wall segment comprising a corner block having a plurality of angularly extending block portions joined to the linear wall segments, the corner block portions each having an identical half groove and half ridge interlocked in a running fit -with the inner faces of the end blocks of a layer of blocks, at least one square faced block having central cross grooves leaving only cor- 8 ner portions of the half ridges, and at leastone of the, References Cited overlapping single grooved blocks in the opposite layer of UNITED STATES PATENTS the wall segment being oriented W1th its groove and half 2 52 568 ridges extending horizontally providing a vertical interlock 1 9 fi g fii z gg 52 586 with one of the corner half ridge portions of sa1d cross 5 3:076:286 2/1963 Czecholinski 52 70 grooved block, the dove-tail grooves and ridges on said blocks having planar faces which are positioned in faceto-face relationship when interlocked to define a close yet HENRY SUTHERLAND Pnmaly Examiner free fit without any noticeable play between interlocked U 5 c1 XR blocks so that the wall is assembled Without a binding 10 agent between blocks. 52284, 570

UNITED STATES PATENT OFFICE CERTIFICATE OF $ZO RRECTION Patent No. 3562989 Dated 5 Eghmmmz Inventor(s) Rest! Gregoire It is certified that error appears in the above-identified pateni and that said Letters Patent are hereby corrected as shown below:

Column 3, cancel lines +8 and +9.

Line 50, change "XXII" to ---XXI--- Line 52, change "XXIII" to ---XXII- Line 55, change "XXIV and XXV" to ---XXIII and XXIV-- Line 58, change "XXVI" te ---XXV......

Line 60, change "XXVII" to ---XXVI--- Line 64, change "XXVIII" to ---XXVII- Line 67, change "XXIX" to ---XXVIII--- Lin 72, ange "xxx" m ---XXIX--- Line 7 1', change "XXXI" t ---XXX- Column line 1 change "XXXII" to ---XXXI-..

Line 8', change "XXXIII" to ---XXXII-..-

Column 5, line 12, change "XII" to ---XIII-- Signed and sealed this 29th day of June 1971.

(SEAL) Attest:

EDWARD M.FLETGHER,JR. WILLIAM E. SGHUYLER, Attesting Officer Commissioner of Pater 

